The Three Dimensional Engineered Preform Process (3-DEP) is an innovative, high volume method for making chopped-fiber preforms. The key to the process is a slurry molding machine in which the forming tool is supported on a gimbaled mount. The process can independently control three major forming parameters: (1) flow velocity in the slurry tank, (2) motion of the forming tool, and (3) vacuum level in the forming tool. The ability to manipulate these three parameters provides control over the amount and distribution of fiber deposited and the orientation of those fibers. The process works well with carbon, glass, aramid, and natural fibers. Initial work focused on an automotive part, the "B"-pillar, which is a T-shaped part about 18 by 18 x 3 inches in overall dimensions with multiple curved surfaces. The "B"-pillar was successfully molded in PAN-derived carbon, fiberglass roving, aramid and natural fibers. Recently, work has been completed on a real-world part, the front wheel house support for the Corvette. The part is being molded in carbon fiber. Results have been quite favorable. Part-to-part density variation is small (<5%) as is within-part density variation (<5%). 3-DEP has also demonstrate the ability to make parts with oriented fibers and with fibers de-sposited in heavier amounts in specified regions of a part.
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